Dual wall airfoil with stiffened trailing edge
An airfoil adapted for use in a gas turbine engine is disclosed herein. The airfoil includes a spar defining an interior space and a cover sheet extending around at least a portion of the spar. The cover sheet is bonded to the spar to define a cooling cavity between the spar and the cover sheet.
Latest Rolls-Royce North American Technologies Inc. Patents:
Embodiments of the present disclosure were made with government support under Contract No. FA8650-07-C-2803. The government may have certain rights.
FIELD OF THE DISCLOSUREThe present disclosure relates generally to gas turbine engines, and more specifically to airfoils used in gas turbine engines.
BACKGROUNDVarious techniques are used to construct airfoils to achieve desired geometries at the trailing edges of the airfoils. Airfoil trailing edge thicknesses may impact the performance of gas turbine engine components including the airfoils. Constructing airfoils to achieve desired airfoil thicknesses and thereby improve the performance of such components remains an area of interest.
SUMMARYThe present disclosure may comprise one or more of the following features and combinations thereof.
An airfoil according to the present disclosure may include a spar. The spar may define an interior space and may include thickened portions creating tabs that define a plurality of outwardly-opening channels at the trailing edge of the airfoil along a suction side of the airfoil.
In illustrative embodiments, the airfoil may include a cover sheet. The cover sheet may extend around at least a portion of the spar. The cover sheet may be bonded to the tabs of the spar to create slots at the trailing edge of the airfoil.
In illustrative embodiments, the slots may open into a cooling cavity defined between the spar and the cover sheet. The cooling cavity may extend along the suction side of the airfoil forward of the tabs.
In illustrative embodiments, the spar may define a central cooling air plenum adapted to be pressurized with cooling air and may be formed to include cooling air passages fluidly coupling the central cooling air plenum to the cooling cavity.
In illustrative embodiments, the tabs may be spaced apart from one another in a radial direction extending along the trailing edge of the airfoil. One of the tabs may extend to an outward-most surface of the spar in the radial direction. Another of the tabs may extend to an inward-most surface of the spar in the radial direction arranged opposite the outward-most surface of the spar.
In illustrative embodiments, the tabs may be shaped so that the outwardly-opening channels diverge as they extend toward the trailing edge of the airfoil.
In illustrative embodiments, a thermal barrier coating may be applied to at least a portion of the cover sheet facing outwardly away from the cooling cavity. The portion of the cover sheet may extend to the trailing edge of the airfoil and forward of the tabs.
According to another aspect of the present disclosure, an airfoil may include a spar. The spar may terminate at a point located forward of a trailing edge of the airfoil.
In illustrative embodiments, the airfoil may also include a cover sheet coupled to the spar to form a cooling cavity between the spar and the cover sheet along at least a portion of a suction side of the airfoil and extending from the point to the trailing edge of the airfoil. The cover sheet may include a thickened portion along the trailing edge of the airfoil formed to include a plurality of slots that extend from the trailing edge of the airfoil to the cooling cavity to fluidly couple the cooling cavity to the trailing edge of the airfoil.
In illustrative embodiments, a thickness of the cover sheet measured forward of the point may be less than a thickness of the cover sheet measured at the trailing edge of the airfoil.
In illustrative embodiments, the slots may be spaced apart from one another in a radial direction extending along the trailing edge of the airfoil.
In illustrative embodiments, the spar may define a central cooling air plenum adapted to be pressurized with cooling air. The spar may be formed to include cooling air passages fluidly coupling the central cooling air plenum to the cooling cavity.
In illustrative embodiments, a notch may be formed in one of the spar and the thickened portion. The other of the spar and the thickened portion may be received by the notch to couple the thickened portion to the spar at the point.
In illustrative embodiments, a thermal barrier coating may be applied to the cover sheet opposite the cooling cavity.
In illustrative embodiments, a cooling path extending through the plurality of slots in a radial direction along the trailing edge of the airfoil may be defined by the thickened portion. In illustrative embodiments, the slots may diverge as they extend toward the trailing edge of the airfoil.
In illustrative embodiments, the cover sheet may be constructed of one or more ceramic matrix composite materials. In some embodiments, the spar may be constructed of one or more metallic materials. In some embodiments, the spar may be constructed of one or more ceramic matrix composite materials
These and other features of the present disclosure will become more apparent from the following description of the illustrative embodiments.
Referring now to
The segment 10 illustratively includes a platform 12 and a platform 14 spaced from the platform 12 in a radial direction indicated by arrow R as shown in
Referring now to
The airfoil 16 illustratively includes a spar 30 that extends from the leading edge 26 to the trailing edge 28 and defines an interior space 32 as shown in
The spar 30 includes thickened portions 38 that create tabs 40 at the trailing edge 28 of the airfoil 16 along the suction side 22 as best seen in
The illustrative airfoil 16 may provide a number of component features, which are described in greater detail below. The stiffness of the spar 30 included in the airfoil 16 may facilitate bonding with the cover sheet 34 and may control deformation of the airfoil 16 in response to experiencing operational loads. The relatively thin thickness of the trailing edge 28 of the airfoil 16 allowed by the disclosed design may facilitate cooling of the airfoil 16 and allow operating efficiency gains for a gas turbine engine including the airfoil 16.
In the illustrative embodiment, the outwardly-opening channels 42 of the spar 30 are features provided solely by the spar 30 as shown in
Referring back to
The spar 30 is illustratively formed to include cooling air passages 48 that extend from the interior space 32 to the cooling cavity 46 as shown in
The cover sheet 34 is illustratively formed to include film cooling holes 35 extending therethrough to fluidly couple the cover sheet 34 to the cooling cavity 46 as shown in
The spar 30 and the cover sheet 34 may have a variety of constructions. In the illustrative example, the cover sheet 34 is constructed of ceramic matrix composite materials and the spar 30 is constructed of metallic materials. In another example, the spar 30 and/or the cover sheet 34 may be constructed of ceramic matrix composite materials. In yet another example, the spar 30 and/or the cover sheet 34 may be constructed of metallic materials. In yet another example still, the spar 30 and the cover sheet 34 may have other suitable constructions.
The airfoil 16 further illustratively includes a thermal barrier coating 52 as shown in
Referring now to
Referring now to
In the illustrative embodiment, the tabs 40 and the outwardly-opening channels 42 have a generally trapezoidal shape as shown in
Referring now to
The radially outward-most tab 56 illustratively includes a planar top wall 64 that is directly interconnected with the radially outward-most surface 58 as best seen in
As best seen in
The radially inward-most tab 60 illustratively includes a planar bottom wall 74 that is directly interconnected with the radially inward-most surface 62 as shown in
As shown in
The tabs 40 further illustratively include central tabs 84 that are spaced from one another in the radial direction indicated by arrow R between the radially outward-most and radially inward-most tabs 56, 60 as shown in
The central tabs 84 illustratively include a tab 86 that is positioned closer to the radially outward-most tab 56 than any of the other tabs 84 as best seen in
The tab 86 of the central tabs 84 illustratively includes a planar top wall 90 and a planar bottom wall 92 that is arranged opposite the top wall 90 as shown in
As best seen in
The outwardly-opening channels 42 illustratively include a radially outward-most channel 100, a radially inward-most channel 102, and central channels 104 as shown in
The radially outward-most channel 100 is illustratively defined by the radially outward-most tab 56, the tab 86, and a surface 106 that interconnects the tabs 56, 86 as best seen in
The radially inward-most channel 102 is illustratively defined by the radially inward-most tab 60, the tab 88, and a surface 108 that interconnects the tabs 60, 88 as shown in
The central channels 104 are illustratively defined by the central tabs 84 and surfaces 110 that interconnect the tabs 84 as shown in
Divergence of the channels 100, 102, 104 as they extend toward the trailing edge 28 of the airfoil 16 may impact the amount of heat transferred from the airfoil 16 to the cooling air conducted through the channels 100, 102, 104. As the channels 100, 102, 104 diverge toward the trailing edge 28, the area bounded by the channels 100, 102, 104 increases. The amount of cooling air occupying the area bounded by the channels 100, 102, 104 may therefore increase. Because heat transfer from the airfoil 16 to the cooling air contained in the channels 100, 102, 104 increases as the channels 100, 102, 104 diverge, the divergence of the channels 100, 102, 104 may lead to lower operating temperatures of the airfoil 16.
Referring back to
Referring to
Referring again to
Referring yet again to
Referring still to
Referring yet still to
Referring now to
The segment 210 illustratively includes an airfoil 212 as shown in
The airfoil 212 illustratively includes a spar 222 that extends from the leading edge 218 to a point 224 located forward of the trailing edge 220 and defines an interior space 226 as best seen in
The cover sheet 228 and the spar 222 are illustratively coupled together to form a cooling cavity 232 between the cover sheet 228 and the spar 222 as shown in
The slots 236 are illustratively spaced apart from one another in a radial direction indicated by arrow R extending along the trailing edge 220 as shown in
Divergence of the slots 236 as they extend toward the trailing edge 220 of the airfoil 212 may impact the amount of heat transferred from the airfoil 212 to the cooling air conducted through the slots 236. As the slots 236 diverge toward the trailing edge 220, the area bounded by the slots 236 increases. The amount of cooling air occupying the area bounded by the slots 236 may therefore increase. Because heat transfer from the airfoil 212 to the cooling air contained in the slots 236 increases as the slots 236 diverge, the divergence of the slots 236 may lead to lower operating temperatures of the airfoil 212.
The illustrative airfoil 212 may provide a number of component features, which are described in greater detail below. The stiffness of the spar 222 included in the airfoil 212 may facilitate bonding with the cover sheet 228 and may control deformation of the airfoil 212 in response to experiencing operational loads. The relatively thin thickness of the trailing edge 220 of the airfoil 212 allowed by the disclosed design may facilitate cooling of the airfoil 212 and allow operating efficiency gains for a gas turbine engine including the airfoil 212.
The cover sheet 228 and the spar 222 illustratively extend forward of the point 224 to the leading edge 218 and therefrom to the point 230 to define the cooling cavity 232 therebetween as shown in
Referring now to
The cover sheet 228 is illustratively formed to include film cooling holes 229 extending therethrough to fluidly couple the cover sheet 228 to the cooling cavity 232 as shown in
The spar 222 and the cover sheet 228 may have a variety of constructions. In the illustrative example, the cover sheet 228 is constructed of ceramic matrix composite materials and the spar 222 is constructed of metallic materials. In another example, the spar 222 and/or the cover sheet 228 may be constructed of ceramic matrix composite materials. In yet another example, the spar 222 and/or the cover sheet 228 may be constructed of metallic materials. In yet another example still, the spar 222 and the cover sheet 228 may have other suitable constructions.
The airfoil 212 further illustratively includes a thermal barrier coating 242 as shown in
The thickened portion 234 of the cover sheet 228 illustratively includes a segment 244 and a segment 246 interconnected with the segment 244 as shown in
Referring now to
The segments 244 and 246 of the thickened portion 234 illustratively cooperate to partially define a cooling path 250 as shown in
The cooling path 250 extends through the slots 236 in the radial direction indicated by arrow R along the trailing edge 220 of the airfoil 212. Cooling air conducted to the cooling cavity 232 passes through the cooling path 250 as the cooling air is conducted by the slots 236 to the trailing edge 220 during operation of the gas turbine engine.
A thickness t1 of the cover sheet 228 measured forward of the point 224 is illustratively different from a thickness t2 of the cover sheet 228 measured at the trailing edge 220 of the airfoil 212 as shown in
The thickness t2 of the cover sheet 228 at the trailing edge 220 of the airfoil 212 is illustratively about 0.033 inches. The thermal barrier coating 242 illustratively has a thickness t3 of about 0.006 inches at the trailing edge 220. As a result, the trailing edge 220 of the illustrative airfoil 212 has a thickness t4 of about 0.039 inches. In other embodiments, however, the cover sheet 228 and the thermal barrier coating 242 may have other suitable thicknesses. In those embodiments, the trailing edge 220 of the airfoil 212 may have another suitable thickness.
Referring to
Referring again to
Referring yet again to
Referring still to
Referring yet still to
Finally, referring once more to
Existing dual-wall airfoil fabrication methods may bond together airfoil spars and coversheets that may be thin and flexible at their trailing edges. Such flexibility may lead to unbonding of the airfoil components and undesirable airfoil trailing edge geometry following bonding.
The present disclosure may address the drawbacks associated with these existing methods. In one design contemplated by this disclosure, the spar of the airfoil, such as the spar 30 of the airfoil 16, may be thickened at the trailing edge, such as the trailing edge 28. In this design, the pattern layer, such as the cooling cavity 46, may be prevented from contributing to the thickness of the airfoil at the trailing edge, such as the thickness T4 of the airfoil 16 at the trailing edge 28. In another design contemplated by this disclosure, the cover sheet of the airfoil, such as the cover sheet 228 of the airfoil 212, may be thickened at the trailing edge, such as the trailing edge 220. In this design, the pattern layer, such as the cooling cavity 232, may be prevented from contributing to the thickness of the airfoil at the trailing edge, such as the thickness t4 of the airfoil 212 at the trailing edge 220.
The designs contemplated by this disclosure may provide a number of features. For instance, the designs may allow an airfoil having a stiffer trailing edge to be achieved than the airfoils produced using the existing methods. Additionally, the trailing edges of the airfoils contemplated by this disclosure may be thinner than the trailing edges of the airfoils produced using the existing methods. As a result, the airfoils contemplated by this disclosure may be operated at lower temperatures and may allow greater operating efficiencies to be achieved than the airfoils produced using the existing methods.
While the disclosure has been illustrated and described in detail in the foregoing drawings and description, the same is to be considered as exemplary and not restrictive in character, it being understood that only illustrative embodiments thereof have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected.
Claims
1. An airfoil comprising an airfoil shaped spar having a suction side wall, a pressure side wall spaced apart from and arranged opposite the suction side wall, a leading edge, and a trailing edge, the pressure side wall extends between and interconnects the leading edge and the trailing edge of the airfoil shaped spar, the suction side wall extends between and interconnects the leading edge and the trailing edge of the airfoil shaped spar, the pressure side wall, the suction side wall, the trailing edge, and the leading edge of the airfoil shaped spar defining an interior space of the spar that provides a central cooling air plenum adapted to be pressurized with cooling air, and the suction side wall of the spar includes thickened portions creating tabs integrally formed with the spar and located at a terminal end of the trailing edge of the spar and extending from the suction side wall of the spar away from the pressure side wall to define a plurality of outwardly-opening channels at a terminal end of a trailing edge of the airfoil and
- a cover sheet extending around at least a portion of the spar, wherein the cover sheet extends along at least a portion of the pressure side wall, around the leading edge, and along the suction side wall of the spar and bonded to the tabs of the spar to create slots at the terminal end of the trailing edge of the airfoil such that the slots are adapted to open directly to a gas path surrounding the airfoil and such that the tabs form a portion of the terminal end of the trailing edge of the airfoil and are exposed to the gas path,
- wherein the spar and the cover sheet cooperate to define a cooling cavity that extends continuously between the cover sheet and the pressure side wall, the suction side wall, and the leading edge of the spar, the cooling cavity is fluidly connected directly to each of the slots at the trailing edge of the airfoil, the cooling cavity has a larger radial height than a radial height of each of the slots, and the spar is formed to include cooling air passages that fluidly couple the central cooling air plenum defined by the interior space of the spar to the cooling cavity.
2. The airfoil of claim 1, wherein the tabs are spaced apart from one another in a radial direction extending along the trailing edge of the airfoil.
3. The airfoil of claim 1, wherein the tabs are shaped so that the outwardly-opening channels diverge as they extend toward the trailing edge of the airfoil.
4. The airfoil of claim 1, further comprising a thermal barrier coating applied to at least a portion of the cover sheet facing outwardly away from the cooling cavity.
5. The airfoil of claim 4, wherein the portion of the cover sheet extends to the trailing edge of the airfoil and forward of the tabs.
6. An airfoil comprising
- an airfoil shaped spar terminating at a point located forward of a terminal end of a trailing edge of the airfoil, the spar having a suction side wall, a pressure side wall spaced from and arranged opposite the suction side wall, a leading edge, and a trailing edge, the pressure side wall extends between and interconnects the leading edge and the trailing edge of the spar, the suction side wall extends between and interconnects the leading edge and the trailing edge of the spar, and the pressure side wall, the suction side wall, the trailing edge, and the leading edge of the spar define an interior space of the spar that provides a central cooling air plenum adapted to be pressurized with cooling air, and
- a cover sheet extending around at least a portion of the spar and coupled to the spar to form a cooling cavity located between the cover sheet and the pressure side wall, the suction side wall, and the leading edge of the spar and wherein the cover sheet includes a thickened portion that extends beyond the point to the terminal end of the trailing edge of the airfoil, the thickened portion directly contacting the spar, and the thickened portion formed to define entirely therein a plurality of slots that extend from the terminal end of the trailing edge of the airfoil to the cooling cavity to fluidly couple the cooling cavity to each of the plurality of slots at the trailing edge of the airfoil,
- wherein the spar is formed to include cooling air passages that fluidly couple the central cooling air plenum defined by the interior spar of the spar to the cooling cavity and the cooling cavity has a larger radial height than a radial height of each of the plurality of slots.
7. The airfoil of claim 6, wherein a thickness of the cover sheet measured forward of the point is less than a thickness of the cover sheet measured at the trailing edge of the airfoil.
8. The airfoil of claim 6, wherein the slots are spaced apart from one another in a radial direction extending along the trailing edge of the airfoil.
9. The airfoil of claim 6, wherein a concave notch is formed in the spar the thickened portion has a convex surface that is received by the notch to couple the thickened portion to the spar at the point.
10. The airfoil of claim 9, further comprising a thermal barrier coating applied to the cover sheet opposite the cooling cavity.
11. The airfoil of claim 9, wherein a cooling path extending through the plurality of slots in a radial direction along the trailing edge of the airfoil is defined by the thickened portion.
12. The airfoil of claim 6, wherein the slots diverge as they extend toward the trailing edge of the airfoil.
13. The airfoil of claim 1, wherein the trailing edge of the spar has a first thickness in a first direction, the cover sheet has a second thickness in the first direction where the cover sheet is bonded to the trailing edge of the spar, and the second thickness is less than the first thickness.
14. The airfoil of claim 1, wherein the cover sheet extends only partway along the pressure side wall of the spar so that a portion of the pressure side wall of the spar adjacent the trailing edge of the spar forms an outermost surface of the airfoil.
15. An airfoil comprising an airfoil shaped spar having a suction side wall, a pressure side wall spaced apart from and arranged opposite the suction side wall, a leading edge, and a trailing edge, the pressure side wall extends between and interconnects the leading edge and the trailing edge of the airfoil shaped spar, the suction side wall extends between and interconnects the leading edge and the trailing edge of the airfoil shaped spar, the pressure side wall, the suction side wall, the trailing edge, and the leading edge of the airfoil shaped spar defining an interior space of the spar that provides a central cooling air plenum adapted to be pressurized with cooling air, and the suction side wall of the spar includes thickened portions creating tabs integrally formed with the spar and located at a terminal end of the trailing edge of the spar and extending from the suction side wall of the spar away from the pressure side wall to define a plurality of outwardly-opening channels at a terminal end of a trailing edge of the airfoil and
- a cover sheet extending around at least a portion of the spar, wherein the cover sheet extends along at least a portion of the pressure side wall, around the leading edge, and along the suction side wall of the spar and bonded to the tabs of the spar to create slots at the terminal end of the trailing edge of the airfoil such that the slots are adapted to open directly to a gas path surrounding the airfoil and such that the tabs form a portion of the terminal end of the trialing edge of the airfoil and are exposed to the gas path,
- wherein the spar and the cover sheet cooperate to define a cooling cavity that extends continuously between the cover sheet and the pressure side wall, the suction side wall, and the leading edge of the spar, the cooling cavity is fluidly connected directly to each of the slots at the trailing edge of the airfoil, the cooling cavity has a larger radial height than a radial height of each of the slots, and the spar is formed to include cooling air passages that fluidly couple the central cooling air plenum defined by the interior space of the spar to the cooling cavity, and
- wherein the cover sheet has a first trailing edge along a pressure side of the cover sheet with a first thickness and a second trailing edge arranged along the suction side of the cover sheet and aligned with the trailing edge of the airfoil shaped spar, the second trailing edge having a second thickness that is less than the first thickness across the entire radial height of the cooling cavity.
16. The airfoil of claim 6, wherein the cover sheet has a first trailing edge along a pressure side of the cover sheet with a first thickness and a second trailing edge offset aft from the first trailing edge and arranged along the suction side of the cover sheet with a second thickness, and the first thickness is less than the second thickness.
17. The airfoil of claim 16, wherein the first thickness and the second thickness are constant across the radial height of the cooling cavity.
18. The airfoil of claim 16, wherein the plurality of slots are formed entirely within the second trailing edge and the first thickness of the first trailing edge is constant across the radial height of the cooling cavity.
19. The airfoil of claim 6, wherein the thickened portion is formed to include a first semicircular groove and a second semicircular groove spaced apart from the first semicircular groove.
20. The airfoil of claim 19, wherein the first semicircular groove and the second semicircular groove extend through the plurality of slots in a radial direction along the trailing edge of the airfoil to provide a cooling path through the thickened portion.
3726604 | April 1973 | Helms |
4437810 | March 20, 1984 | Pearce |
5259730 | November 9, 1993 | Damlis |
5288207 | February 22, 1994 | Linask |
5384959 | January 31, 1995 | Velicki |
5630700 | May 20, 1997 | Olsen |
5652044 | July 29, 1997 | Rickerby |
6224339 | May 1, 2001 | Rhodes |
6234754 | May 22, 2001 | Zelesky |
6398501 | June 4, 2002 | Darkins, Jr. et al. |
7086829 | August 8, 2006 | Fuller |
7828515 | November 9, 2010 | Kimmel |
7845908 | December 7, 2010 | Liang |
8162617 | April 24, 2012 | Davies et al. |
8366398 | February 5, 2013 | Kimmel |
8608430 | December 17, 2013 | Liang |
8944773 | February 3, 2015 | Weisse |
20030017051 | January 23, 2003 | Coutandin |
20120189427 | July 26, 2012 | Kwon et al. |
20120201653 | August 9, 2012 | Moga |
2246174 | January 1992 | GB |
60192803 | October 1985 | JP |
Type: Grant
Filed: Dec 14, 2016
Date of Patent: Aug 11, 2020
Patent Publication Number: 20180163554
Assignee: Rolls-Royce North American Technologies Inc. (Indianapolis, IN)
Inventor: Mark O'Leary (Zionsville, IN)
Primary Examiner: Woody A Lee, Jr.
Assistant Examiner: Andrew Thanh Bui
Application Number: 15/378,915
International Classification: F01D 9/06 (20060101); F01D 5/18 (20060101); F01D 5/14 (20060101);